SSI Schäfer Automates Ostendorf’s Warehouse in Emstek

In just six months, SSI SCHÄFER has automated the existing mobile shelving system at Ostendorf in Emstek by using Automated Guided Vehicles (AGVs) and the intralogistics software WAMAS®. The positive effects of the semi-automated logistics solution were felt and measurable right from the go-live in mid-2021: error-free and transparent processes as well as a constant, resource-independent, and thus more efficient material flow in a 3-shift operation.

(Neunkirchen/Emstek) Gebr. Ostendorf Kunststoffe GmbH is one of the leading manufacturers of wastewater pipe systems in Germany and has been selling these plastic pipes and fittings made of polypropylene since 1973. The construction industry is the main customer, typically ordering large quantities in various variants and operating in a cost-intensive environment. In light of ongoing growth and the demand for ever-shorter delivery times, Ostendorf had already put a new central distribution center into operation at its headquarters in Vechta in 2017. It is designed for optimally packaged overnight delivery of goods and was equipped by SSI SCHÄFER with an automatic channel storage system, including SSI Orbiter® load handling devices, intralogistics software WAMAS®, and conveyor technology.

At the Emstek location, Ostendorf was also challenged to adapt processes to increasingly demanding market conditions. Intralogistics processes needed to be optimized, productivity increased, and costs reduced. At the same time, a main customer from the construction industry had contractually agreed to pre-commission goods on mixed pallets. In this context, suddenly more packaging materials and pallets needed to be held and moved in the warehouse. However, suitable personnel for the associated additional workload and for a 3-shift operation is scarce—especially in the Oldenburg Münsterland, where nearly full employment prevails. Thus, Ostendorf opted for a semi-automated and quickly installable plug & play solution from SSI SCHÄFER, which is particularly well-suited for smaller warehouses with moderate throughput: The new solution with the driverless transport systems (FTS) in conjunction with the existing mobile shelving system (VRS) reliably covers the inbound and outbound processes as well as the internal transports. Ostendorf thus benefits from high process reliability around the clock.

One Partner as General Contractor

The decision was made in favor of SSI SCHÄFER because Ostendorf wanted only one partner as the general contractor for the entire solution, including all interfaces. This significantly facilitated communication and ensured a time-optimized project progression. Furthermore, they could look back on good cooperation in other projects, such as the high-bay warehouse in Vechta and the pallet mobile shelving system in Rain am Lech. In implementing the projects, SSI SCHÄFER proved to be a reliable and competent partner. Finally, Ostendorf was already familiar with the intralogistics software WAMAS® from the Vechta location and had had good experiences with it.

“The wish to implement full automation analogously to Vechta would have been exaggerated for Emstek,” reports Ludger Stroot, plant manager at Ostendorf in Emstek. “But we still wanted to automate to a certain extent to retain the associated benefits. The driverless transport systems were the right technology in this context and perfectly suited for the comparatively low throughput.” “Moreover, time was pressing,” adds Lukas Varelmann, head of internal logistics at Ostendorf. “While planning and implementing a fully automated high-bay warehouse, including building application, takes at least three years, we achieved our set goals in less than six months thanks to partial automation.”

Directly Integrable into Logistics Structures

Such a manageable time frame highlights the special advantages of the introduced scalable logistics solution: “The combination of the mobile shelving system and the driverless transport system is mature as a standard and can be directly integrated into the customer’s warehouse structures,” explains Stefan Reichwald, sales manager at SSI SCHÄFER. “Thus, the solution for automated pallet handling has immediate positive effects on delivery reliability and quality as well as on ongoing operating costs.”

The partial automation project was successfully completed by SSI SCHÄFER together with AGV specialist DS Automotion, a company of the SSI SCHÄFER Group, in mid-2021. The partners set up an interface to the existing mobile shelving system. At the same time, they were responsible for integrating the AGVs, the conveyor technology, and the overall integration into Ostendorf’s WAMAS® software environment. “Including software, this was a comprehensive solution package. Therefore, the decision to implement it in this form was easy for us,” emphasizes Lukas Varelmann.

Material Flow in 3-Shift Operation

“The AGVs enable Ostendorf to maintain a constant material flow in 3-shift operation, the processes are clearly structured, and errors are nearly excluded,” explains Roland Hieslmair, sales engineer at DS Automotion. This relieves the employees, who today take on cross-process activities in the control center, among other things. Furthermore, all processes are clearly traceable via WAMAS®. The secure, reliable communication between VRS and AGVs also prevents waiting times: As the vehicle approaches the target aisle, it is already triggered to open.

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